Theoretical and experimental analysis of springback compensation for four-roll roll forming

Abstract The four-roll bending machine is large-scale bending equipment. It has a wide range of applications in various engineering industries.Rebound is an unavoidable phenomenon in the process of profile roll forming, which directly affects the processing accuracy of the profile.In order to improve the forming quality of four-roll bending machine bending profiles after rebound, the forming process flow is first analyzed, and according to the relationship between its four-roll bending and side roll displacement, the establishment of a mathematical model of the side roll displacement in the state of no rebound; Secondly, the Bouhêlier rebound equation is combined with the mathematical equation of side roll displacement to obtain the theoretical forming radius-side roll displacement relationship equation and finite element simulation to verify; Then, through the prototype of the actual roll forming, the measured roll forming data through MATLAB processing, through the Power function fitting to get the actual forming radius - side roll displacement relationship and generate functional equations, and with the theoretical forming radius - side roll displacement of the relationship between the equation combined with the final elasticity of the compensation value of the equation;Finally, the elastic compensation value equation is verified practically by the prototype machine, and the results are good and meet the expected requirements.